Mailpieces that mitigate flexure of held articles during automated handling

ABSTRACT

Mailpieces configured to mitigate flexure of frangible articles during handling by postal processing equipment. The mailpieces include spacers that intervene between the stress-sensitive article held by the mailer and a convex surface of a roller, drum, spindle, or other mechanical device used in the postal processing equipment for transporting the mailpieces.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of application Ser. No.11/610,675, filed on Dec. 14, 2006, which claims the benefit of U.S.Provisional Application No. 60/805,416, filed Jun. 21, 2006, thedisclosure of each document is hereby incorporated by reference hereinin its entirety.

FIELD OF THE INVENTION

The invention relates to mailpieces and, in particular, to mailpiecesand mailpiece assemblies that are suitable for securing and protectingarticles, such as stress-sensitive or frangible articles, to ensure safeprocessing by automated processing equipment.

BACKGROUND OF THE INVENTION

Mailpieces are routinely employed for mailing breakable, frangible orstress-sensitive articles, such as DVD's, compact disks (CD's), andmini-CD's. Most mass mailings of frangible articles consist ofletter-sized mailpieces, which are pre-sorted before possession istransferred to a postal service, such as the United States PostalService. The pre-sorting qualifies the mass mailing for reduced postagerates because it easier for the United States Postal Service to sort anddeliver the mail using automated equipment. To qualify for reducedpostage rates, however, the processed mail must meet certain criteriaset forth in various postal regulations.

Postal services sort large volumes of mail with high-speed automatedprocessing equipment having drums, transport rollers, and pairs ofopposing belts that grip and transport individual mailpieces at a volumeof up to 40,000 pieces an hour. The automated processing equipmentconveys the mailpieces at speeds approaching 500 to 600 feet per minutealong a feed path. Various functions may be performed on the mailpiecesat different locations along the feed path. For example, an opticalscanner provided adjacent to the feed path identifies a destinationaddress for each mailpiece. Ultimately, the mailpieces are sortedaccording to the destination address and routed along the feed path intoassorted bins or stackers.

The rollers used to support the belts, which have a width approximatelyequal to the roller height, are crowned. The vertical convex shape ofthe crowned rollers keeps the belts tracking properly within themachinery and in the correct position on the rollers. The opposing beltsare kept under tension to be able to hold and transport mailpiecesthrough the machinery of the automated processing equipment. As thebelts move through and change direction within the machinery, thetension of the belts exerts pressure on the rollers. Changes indirection are accommodated by providing a pulley, roller or drum overwhich the moving belts are trained at the change-of-direction point. Forexample, if the mailpiece is moving linearly in a horizontal directionand it is desired to effect a directional change to a differenthorizontal direction, a rotatable drum is placed at thechange-of-direction point in the path of travel of the opposed belts. Asthe belts move about the rotating drum, the mailpiece travels through acurved path conforming to the drum periphery and emerges travelingbetween the moving belts in the different horizontal direction.

Letter-size mailpieces are constructed to comply with postalregulations, such as dimensional requirements, address positioning, andflexibility. Specifically, postal regulations require the mailpiece tobe flexible enough to be bent and routed about the circumference ofcylindrical pulleys, rollers and drums of the type used in automatedprocessing systems. The United States Postal Service currently statesthat all letter-sized mailpieces must easily bend under 40 pounds ofexerted belt pressure. If the dimensions of the mailpiece exceed amaximum dimension (e.g., are oversized) as governed by postalregulations or the mailpiece fails to meet the flexibility requirementsfor letter sorting equipment, the United States Postal Service does nottreat the mailpiece as a letter. Instead, the mailpiece is handled as anon-letter or flat by automated equipment that does not require routingabout the exterior of drums or rollers. The postage rate is higher forflats than for letter-sized mailpieces.

Conventional mailpieces expose stress-sensitive articles to asignificant risk of damage during processing by automated processingequipment. As the mailpiece is conveyed about the exterior of the roller(or pulley or drum), the belt pressure forces flexible items carried bythe belts to conform to the vertical convex shape of the roller and tobend or bow horizontally around the circumference of the roller when thebelt changes direction. The stress-sensitive article inside themailpiece must also curve or bow in conformity with the mailpiece and,therefore, will experience a state of tension due to the flexure. Thecombination of bending to the vertical convex shape of the roller andbending horizontally around the circumference of the roller is believedto apply significant pressure on the article at the center of these twodivergent forces. The applied pressure may damage, or even break orfracture, the article.

With reference to FIGS. 1, 2, and 3, a pair of confronting conventionalbelts 11 (one shown) rides over the surface of a vertically-orientedcrown roller 12 mounted with bearings to an axle or spindle 15projecting from the support base of a machine 17. The roller 12 is oneof several similar rollers (not shown) used for guiding the belts 11 ina generally horizontal direction indicated by the single-headed arrows14. As the belts 11 move in the horizontal direction 14, the belts 11cause the crown roller 12 to rotate about an axis 15 a (FIGS. 2, 3), asindicated by the single headed arrow 113 in FIG. 3. Crown roller 12includes a convexly-contoured surface 13 such that the diameter ofroller 12 at a circumference 26 is larger than the diameter of roller 12at peripheral rims 30 a, 30 b.

A stress-sensitive, frangible article 16, which is contained or packagedinside of a mailpiece 22, is gripped on opposites sides by the movingbelts 11. Frangible article 16 may be, but is not limited to, a CD, DVD,optical disk, or the like, having a hub 18, a center opening 21 definedin the hub 18, and a media portion 20. The hub 18 and media portion 20are concentrically arranged about a central axis 19 of the centeropening 21 with the hub 18 radially inside of the media portion 20.

Mailpiece 22, which may have a generally rectangular shape, has aheight, h, (FIG. 4) greater than the height of article 16, a length, L,and a thickness, w. The length, L, is measured generally along thehorizontal direction of travel 14. Mailpiece 22 includes two opposedpanels 42, 44, peripheral edges 46, 48 substantially parallel to thelength, L, and lateral or side edges 50, 52 substantially parallel tothe height, h. The peripheral edges 46, 48 (FIG. 4) respectivelyrepresent the top and bottom edges of the mailpiece 22 when beingconveyed by the belts 11. The side edges 50, 52 connect the peripheraledges 46, 48. Peripheral edge 46 may coincide with a fold line 47 of aflap 56 (FIG. 7).

The mailpiece 22 and frangible article 16 are conveyed past the crownroller 12. As the belts 11 past the crown roller 12 in the horizontaldirection 14 transport the mailpiece and frangible article 16, the hub18 and/or media portion 20 of the article 16 generally ride over thesurface 13 of the roller 12. The mailpiece 22 prevents direct contactbetween the article 16 and belts 11. At any instant in time, themailpiece 22 contacts the roller 12 about contact point 24, which lieson a circumference 26 of the roller 12. As best shown in FIG. 2A,mailpiece 22 moves into and out of the plane of the page in a directiongenerally parallel to a plane 36 that is tangent to contact point 24.The moving belts 11 apply belt pressure in a direction generallyindicated by arrows 28 to the mailpiece 22. As the mailpiece 22 istransported past the roller 12, contact point 24 traces a substantiallylinear path along the length, L, of the mailpiece 22.

Frangible article 16 is typically carried inside mailpiece 22 with atleast a portion of the hub 18 located between the opposite rims 30 a, 30b of roller 12. The mailpiece 22 and the article 16, which are somewhatflexible, conform to the convexly contoured surface 13 of the crownroller 12 between peripheral rims 30 a, 30 b under the influence of thebelt pressure 28. Specifically, mailpiece 22 and article 16 bend or flexto adopt a convex curvature that corresponds to the convexly contouredsurface 13 of the crown roller 12. Because of the curvature of thesurface 13 of crown roller 12, the belt pressure 28 bends the mailpiece22 and article 16 in a direction perpendicular to the travel direction14. The bending of the mailpiece 22 and article 16 closes thetheoretical gaps 32 a, 32 b (FIG. 2A) defined by the respectivedistances from points 39 a, 39 b on the rims 30 a, 30 b to the nearestpoint along the plane 36, otherwise present in the absence of pressuresymbolized by arrows 28. Each of the panels 42, 44 (FIG. 4) defining themailpiece 22, which is relatively thin, operates as a thin membrane orfilm that readily conforms to the shape of the roller 12.

As best shown in FIG. 3, the mailpiece 22 also bends about thecircumference 26 (FIG. 2) of the roller 12 to conform to the curvature.The frangible article 16, which is constrained by the mailpiece 22, mustlikewise flex to assume a curvature that conforms to the circumference26 of the roller 12. Consequently, the belt pressure 28 also bends thearticle 16 about the roller 12 in a direction parallel to the traveldirection indicated by arrow 14.

The bi-directional flexing of the mailpiece 22 and frangible article 16may damage the frangible article 16. In one damage mode, the flexing maycause a fracture to initiate and propagate in the constituentmaterial(s) of the frangible article 16. Often, the fracture willinitiate in the hub 18 and propagate radially outwardly into the mediaportion 20. The fractured hub 18 of the frangible article 16 may bedamaged to an extent that the frangible article 16 cannot be engaged bya player for retrieving the data encoded in the medial potion 20.Alternatively, the fracture may damage the media portion 20 such thatany data encoded in the media portion 20 is unreadable by the player.Because of this and other significant shortcomings, conventionalletter-sized mailpieces fail to adequately safeguard stress-sensitivearticles when handled by automated processing equipment of the type usedby the United States Postal Service.

Accordingly, there is a need for mailpieces and mailpiece assembliessuitable for mailing stress-sensitive, frangible articles that can behandled by automated letter-sized processing equipment and, moreover,that fully comply with postal regulations while simultaneouslyprotecting the article from damage during processing.

SUMMARY OF THE INVENTION

In one embodiment, a mailpiece is provided for mailing an article havinga first side and a second side opposite to the first side. The mailpiececomprises first and second panels that are joined to define a firstperipheral edge, a second peripheral edge, and side edges separating thesecond peripheral edge from the first peripheral edge. The first andsecond panels are disposed on the respective opposite sides of thearticle and the article is positioned between the first and secondedges. The first panel carries a first spacer. The second panel carriesa second spacer. The first spacer is disposed between the first side ofthe article and the first panel. The second spacer is disposed betweenthe second side of the article and the second panel. The first andsecond spacers are aligned substantially parallel to the first andsecond peripheral edges.

In another embodiment, a mailpiece is provided for mailing an articlehaving a first side and a second side opposite to the first side. Themailpiece comprises a first panel, a second panel joined to the firstpanel to define a first peripheral edge, a second peripheral edge, andside edges separating the second peripheral edge from the firstperipheral edge. The mailpiece further includes a sleeve carrying thearticle. The sleeve is disposed between the first and second panels. Thesleeve is also positioned between the first and second edges. The sleeveincludes a first spacer disposed between the first side of the articleand the first panel, and a second spacer disposed between the secondside of the article and the second panel. The first and second spacersare aligned substantially parallel to the first and second peripheraledges.

In another embodiment, a mailpiece is provided for mailing an articlehaving a first side and a second side opposite to the first side. Themailpiece comprises a first panel joined to a second panel to define afirst peripheral edge, a second peripheral edge, and side edgesseparating the second peripheral edge from the first peripheral edge.The first and second panels are disposed on the respective oppositesides of the article. The article is positioned between the first andsecond edges. An insert is located between the first and second panels.The insert includes a first spacer disposed between the first side ofthe article and the first panel and a second spacer disposed between thesecond side of the article and the second panel. The first and secondspacers may be aligned substantially parallel to the first and secondperipheral edges.

In another embodiment, a mailpiece is provided for mailing an articlehaving a first side and a second side opposite to the first side. Themailpiece comprises a first panel joined to a second panel to define afirst peripheral edge, a second peripheral edge, and side edgesseparating the second peripheral edge from the first peripheral edge.The first and second panels disposed on the respective opposite sides ofthe article. The article is positioned between the first and secondedges. First and second inserts are disposed between the first andsecond panels. The first insert includes a first spacer disposed betweenthe first side of the article and the first panel. The first insertincludes a second spacer disposed between the second side of the articleand the second panel. The first and second spacers are alignedsubstantially parallel to the first and second peripheral edges.

In another embodiment, a mailpiece is provided for mailing an articlehaving a first side, a second side opposite to the first side, and acenter opening extending between the first and second sides. Themailpiece comprises a first panel joined to a second panel to define afirst peripheral edge, a second peripheral edge, and side edgesconnecting the first and second peripheral edges. The first and secondpanels are disposed on the respective opposite sides of the article. Thearticle is positioned between the first and second edges. A spacer,which may be carried by the first panel, is adapted to be inserted intothe center opening of the article. The spacer is at least partiallydisposed between the first side of the article and the first panel.

In another embodiment, an apparatus for use with a mailpiece thatcomprises a frangible article having a first side and a second sideopposite to the first side. The apparatus further comprises a spacerprojecting from the first side of the frangible article. The spacer isadapted to be disposed between the first side of the frangible articleand the mailpiece.

The spacers of the embodiments of the invention operate to reduce onecomponent of the bi-directional flexing of the mailpiece and thefrangible article carried by the mailpiece. Specifically, the spacersreduce the flexing of the mailpiece and frangible article relative tothe convexly contoured surface of a crown roller. This reduces thelikelihood that the frangible article will be damaged when handled byautomated letter-sized processing equipment.

The invention may be used in conjunction with mailpieces shown anddescribed in U.S. Pat. No. 6,491,160 and in U.S. Publication Nos.2004/256446 and 2005/224566. The respective disclosure of each of thesepatent documents is hereby incorporated by reference herein in itsentirety.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention and,together with a general description of the invention given above and thedetailed description of the embodiments given below, serve to explainthe principles of the invention.

FIG. 1 is an elevational view of an article being transported by beltsriding on a crown roller with a mailpiece, which is omitted for purposesof illustration, in accordance with the prior art.

FIG. 2 is an end view of an article held by a mailpiece in accordancewith the prior art in which the mailpiece is being conveyed by beltspast a crown roller and is distorted by the pressure applied by thebelts in which bending about the roller is uncompensated.

FIG. 2A is a theoretical end view similar to FIG. 2 of the prior artmailpiece and the article in the absence of pressure applied by thebelts.

FIG. 3 is a top view of FIG. 2 demonstrating the bending of the priorart mailpiece and article about the circumference of the crown rollerand taken along a line through a circumference of the crown roller.

FIG. 4 is an end view of a mailpiece in accordance with an embodiment ofthe invention in which the mailpiece carries gap-filling spacers atrespective locations above and below the central circumference of theroller.

FIG. 5A is an end view similar to FIG. 4 of a mailpiece in accordancewith an embodiment of the invention.

FIG. 5B is an end view similar to FIG. 5A in which the mailpiece isconveyed past the roller with a different side of the mailpiece incontact with the roller.

FIG. 6 is an end view similar to FIG. 4 of a mailpiece in accordancewith another embodiment of the invention.

FIG. 7 is a perspective view of a mailpiece in accordance with anembodiment of the invention and broken away to show an article held bythe mailpiece.

FIG. 7A is an enlarged view of the encircled area of FIG. 7.

FIG. 8 is an end view of the mailpiece of FIG. 7.

FIGS. 9-12 are detailed perspective views similar to FIG. 7A ofmailpieces in accordance with alternative embodiments of the invention.

FIG. 13A is a perspective view of a mailpiece comprising an envelope anda sleeve inserted into the envelope in accordance with an alternativeembodiment of the invention.

FIG. 13B is an end cross-sectional view of the mailpiece of FIG. 13A.

FIG. 13C is a perspective view of a sleeve for the mailpiece of FIG. 13Ain accordance with an alternative embodiment of the invention.

FIG. 13D is an end cross-sectional view of the sleeve of FIG. 13C.

FIGS. 14-16 are perspective views of mailpieces in accordance withalternative embodiments of the invention.

FIG. 17 is a partial perspective view of a mailpiece in accordance withan embodiment of the invention.

FIG. 18 is a partial perspective view of a portion of a mailpiece inaccordance with an embodiment of the invention.

FIG. 19 is a partial perspective view of a mailpiece in accordance withan alternative embodiment of the invention.

FIG. 20 is a cross-sectional view of the mailpiece of FIG. 19 with thefrangible article and spacer inserted into the mailpiece.

FIG. 20A is an enlarged cross-sectional view of a portion of FIG. 19.

FIG. 20B is an enlarged partial cross-sectional view similar to FIG. 20Aof a mailpiece in accordance with an alternative embodiment.

FIG. 20C is an enlarged partial cross-sectional view similar to FIGS.20A and 20B of a mailpiece in accordance with an alternative embodiment.

FIG. 21A is an end cross-sectional view of the mailpiece of FIGS. 20 and20A held by belts and being transported past a crown roller.

FIG. 21B is an end cross-sectional view similar to FIG. 21A with theopposite panel of the mailpiece riding over a crown roller.

FIG. 22A is a perspective view of a frangible article in accordance withan embodiment of the invention.

FIG. 22B is a partial end cross-sectional view of the frangible articleof FIG. 22A.

DETAILED DESCRIPTION

With reference to FIG. 4 in which like reference numerals refer to likefeatures in FIGS. 1-3 and in accordance with an embodiment of theinvention, a mailpiece 23, which is similar in most respects tomailpiece 22, includes spacers 38 a, 40 a disposed above contact point24 and spacers 38 b, 40 b that are disposed below contact point 24. Thespacers 38 a,b and 40 a,b are aligned generally parallel to theperipheral edges 46, 48.

Spacers 38 a and 38 b are spaced vertically along the height, h, of themailpiece 23 relative to contact point 24, as are spacers 40 a and 40 b.The article 16, spacers 38 a,b, and spacers 40 a,b are positioned withinthe mailpiece 23 such that the circumference 26 of the crowned roller 12(and, thus, the linear path traced by contact point 24 across thelength, L, of the mailpiece 23 between lateral edges 50, 52 (FIG. 7)) isbetween spacers 38 a and 38 b and is also between spacers 40 a and 40 b.Typically, spacers 38 a, 40 a and spacers 38 b, 40 b are positionedwithin mailpiece 23 such that the central axis 19 of the article 16 islocated between spacers 38 a, 40 a and spacers 38 b, 40 b. However, theprecise location of the central axis 19 of the article 16 relative tospacers 38 a, 40 a and spacers 38 b, 40 b is contingent upon thepositioning of the article 16 inside the mailpiece 23 and the locationof the spacers 38 a, 40 a and spacers 38 b, 40 b. Accordingly, thearticle 16 may be positioned inside the mailpiece 23 to optimize theeffectiveness of the spacers 38 a,b, 40 a,b in view of all mailpiecedesign parameters. For example, inserts or a pocket (not shown) may beused to position the article 16 inside the mailpiece 23 to optimize theeffective of the spacers 38 a,b, 40 a,b. Spacer 38 a may be collinear ornon-collinear with spacer 40 a. Similarly, spacer 38 b may be collinearor non-collinear with spacer 40 b.

Spacers 38 a,b, and spacers 40 a,b have a thickness, t₁, measuredrelative to the thickness, w, of the mailpiece 23 that is selected tokeep the frangible article 16 from being forced to conform to thevertically convex (i.e. crowned) surface 13 of the roller 12, as well asthose of other rollers, drums, spindles or mechanical apparatus (notshown) used in postal processing equipment. Spacers 38 a,b, and spacers40 a,b locally increase the thickness of mailpiece 23 and represent aminor deviation from planarity of the side surfaces of panels 42, 44nearest to the article 16. The respective thicknesses, t₁, of thespacers 38 a,b, and spacers 40 a,b is suitably chosen to provide theamount of filler required to at least partially bridge one or both ofthe gaps 32 a, 32 b (FIG. 2A). This reduces the bending or conforming ofthe article 16 relative to the crowned surface 13 of the roller 12 andalong the height of the roller 12. In certain embodiments, the curvatureof the crown on roller 12 is slight so that the spacers 38 a,b, andspacers 40 a,b may be relatively thin, such as, for example, thethickness of two or three sheets of folded paper, or in the range ofabout 1/16″ to about 1/32″.

Spacers 38 a,b are disposed between one side of article 16 and panel 44.Spacers 40 a,b are disposed between the opposite side of the article 16and panel 42. Article 16 is disposed between spacers 38 a and 40 a,which are positioned within the mailpiece 23 and relative to article 16such that the portion of panel 42 adjacent to spacer 40 a contacts theroller 12 between the peripheral rim 30 a and contact point 24 on thecircumference 26. Spacers 38 b and 40 b are positioned within themailpiece 23 and relative to article 16 such that the portion of panel42 adjacent to spacer 40 b contacts the bottom of roller 12 between theperipheral rim 30 b and contact point 24 on the circumference 26.

Spacers 38 a,b operate to reduce the amount of flexing of the article 16because of the tendency of the mailpiece 23 to conform to the crownedsurface 13 of the roller 12. Thus, in the arrangement depicted in FIG.4, the surface 13 of the roller 12 contacts the side surface of panel42, while the surface 13 of the roller 12 may contact the side surfaceof panel 44 if the mailpiece 23 were oriented on the opposite side ofthe roller 12 (such orientation not shown but similar to FIGS. 5A,B).Positioning of one or more of spacers 38 a,b, 40 a,b on each side of thearticle 16 ensures that the article 16 will be protected againstexcessive bending regardless of whether or not edge 46 is the top orbottom edge, and regardless of whether panel 42 or panel 44 is incontact with the roller 12.

The design of the mailpiece 23 and the requirements for effectivelylimiting the amount of bending and flexing of the article 16 maydetermine the number of spacers 38 a,b, 40 a,b. In certain embodiments,fewer than all of the multiple spacers 38 a,b, 40 a,b may be required.Spacers 38 a,b, 40 a,b may be contained within the plane of themailpiece 23 or may project as short asperities (e.g., parallel ridges)from the opposite sides of the mailpiece 23 and inwardly toward thearticle 16 inside the mailpiece 23.

The mailpiece 23 may conform to the shape of the crowned surface 13 onthe crowned roller 12 between the spacers 38 a and 38 b, if the exposedside of panel 44 contacts the roller 12, or between spacers 40 a and 40b, if panel 42 contacts the roller 12. The spacers 38 a,b, 40 a,b areshaped and have a thickness, t₁, sufficient to mitigate the effect ofthe curvature in the crowned roller 12 or other crown-profiled beltsupport members that may be used for proper carriage and tracking ofdrive belts (not shown) in mail or postal processing equipment. Bykeeping the article 16 from being forced to conform to the convex shapeof the crowned roller 12 along the height, h, of the mailpiece 23 at thesame time the article 16 is bending about the circumference 26 of theroller 12, damage to the article 16 may be eliminated or, at the least,the probability is reduced that article 16 will be damaged by the effectof conforming to the surface 13 of roller 12.

Spacers 38 a,b, 40 a,b may be sized and shaped to orient the frangiblearticle 16 substantially parallel to a tangent plane 36 when pressure 28is exerted. Spacers 38 a,b, 40 a,b may be integrally formed or attachedto a mailpiece such as mailpiece 23 or may alternatively be made part ofa sleeve or similar device holding the article 16 such that the sleeveor similar device is placed inside a mailpiece 23 for mailing. Likewise,spacers 38 a,b, 40 a,b may alternatively be made part of or be attachedto the article 16 prior to being inserted into a mailpiece 23.

Spacers 38 a,b, 40 a,b may be rigid and non-compressible, such that nodeformation occurs under the influence of the belt pressure 28 andthickness, t₁, is maintained. Alternatively, the spacers 38 a,b, 40 a,bmay be substantially rigid, such that negligible deformation occursunder the influence of the belt pressure 28 and thickness, t₁, issubstantially maintained. In an alternative embodiment, if the spacers38 a,b, 40 a,b are non-rigid, their thickness is chosen to compensatefor any deformation that occurs under the influence of the belt pressure28 such that the compressed thickness, t₁, is sufficient to mitigate theflexing. Any cushioning effect provided by the spacers 38 a,b, 40 a,b isincidental to the mitigation of the flexing of the article 16.

With reference to FIGS. 5A and 5B in which like reference numerals referto like features in FIGS. 1-4 and in accordance with an alternativeembodiment of the invention, a generally rectangular mailpiece 54, whichis similar in most respects to mailpiece 22, includes two spacers 37 a,bthat separate the article 16 from the panels 42, 44. In this embodiment,spacers 37 a,b are sized and positioned within mailpiece 54 in such amanner as to engage roller 12 providing a straight surface against whicharticle 16 will be pressed when the belt pressure 28 is exerted on thearticle 16. As a result, bending of the article 16 in accordance withthe crowned surface 13 of the roller 12 is limited, which mitigates theflexure of the article 16.

Spacers 37 a,b may be integrally formed or attached to mailpiece 54 ormay alternatively be made part of a sleeve or similar device holding thearticle 16 such that the sleeve or similar device is placed inside amailpiece such as the conventional mailpiece 22 (FIGS. 1-3) for mailing.Likewise, spacers 37 a,b may alternatively be made part of, or may beattached to, the frangible article 16 prior to being inserted into amailpiece. The materials and dimensions of spacers 37 a,b may besuitable chosen to limit bending of article 16. Spacers 37 a,b may, forexample, comprise a thickness, t₂, measured in the same direction as thewidth, w₂, of mailpiece 54 that is larger, smaller or equal to thewidth, w₂. The thickness, t₂, of spacers 37 a,b may greater than thethickness, t₁, of spacers 38 a,b, 40 a,b (FIG. 4).

Spacers 37 a,b may be rigid and non-compressible, such that nodeformation occurs under the influence of the belt pressure 28.Alternatively, the spacers 37 a,b may be substantially rigid, such thatnegligible deformation occurs under the influence of the belt pressure28 and thickness, t₂, is substantially maintained. In an alternativeembodiment, if the spacers 37 a,b are non-rigid, their thickness ischosen to compensate for any deformation that occurs under the influenceof the belt pressure 28 such that the compressed thickness, t₂, issufficient to mitigate the flexing. Any cushioning effect provided bythe spacers 38 a,b, 40 a,b is incidental to the mitigation of theflexing of the article 16.

Typically, the central axis 19 of the article 16 is located betweenspacers 37 a,b. However, the precise location of the central axis 19 ofthe article 16 relative to spacers 37 a,b is contingent upon thepositioning of the article 16 inside the mailpiece 23 and thepositioning of the spacers 37 a,b inside the mailpiece 23. Accordingly,the article 16 may be positioned inside the mailpiece 23 to optimize theeffectiveness of the spacers 37 a,b in view of all mailpiece designparameters. For example, inserts or a pocket (not shown) may be used toposition the article 16 inside the mailpiece 23 to optimize theeffective of the spacers 37 a,b.

With specific reference to FIG. 5A, the belt pressure 28 on themailpiece 54 and the article 16 will result in the article 16 beingtilted such that article 16 is pushed against a portion of panel 42between the rim 30 a and contact point 24 of the roller 12 and againstspacer 37 b. This force profile is such that the bending or flexure ofthe article 16 along the height, h, of the mailpiece 54 is reduced, oreliminated, as mailpiece 54 is transported past the roller 12.

With specific reference to FIG. 5B, the mailpiece 54 rides over thesurface of roller 12 with an outer surface of the opposite panel 44riding against the surface 13. The belt pressure 28 on the mailpiece 54and the article 16 will result in the article 16 and mailpiece 54 beingtilted such that article 16 is pushed against a portion of panel 44between the rim 30 b and circumference 26 of the roller 12 and againstspacer 37 a. This force profile is such that there is reduced bending orflexure of the article 16 along the height, h, of the mailpiece 54 asmailpiece 54 is transported past the roller 12.

With reference to FIG. 6 in which like reference numerals refer to likefeatures in FIGS. 1-5 and in accordance with an alternative embodimentof the invention, a generally rectangular mailpiece 64, which is similarin most respects to mailpiece 22, includes a pair of spacers 37 c,d onthe same side of the contact point 24. The position of the spacers 37c,d may be adjusted so that they lie either above or below contact point24. The spacers 37 c,d are sized, including a thickness, t₃, andpositioned in such a manner as to engage roller 12 providing a straightsurface against which article 16 will be pressed when the belt pressure28 is applied to the article 16. Accordingly, the article 16 may bepositioned inside the mailpiece 23 to optimize the effectiveness of thespacers 37 c,d in view of all mailpiece design parameters. For example,inserts or a pocket (not shown) may be used to position the article 16inside the mailpiece 23 to optimize the effective of the spacers 37 c,d.The spacers 37 c,d, thereby limit bending of the article 16 about thecrowned surface 13 of the roller 12 along the height, h, of themailpiece 64.

The belt pressure 28 exerted on the mailpiece 64 and the article 16 willresult in the article 16 and mailpiece 64 being canted or tilted suchthat article 16 is pushed against a portion of the mailpiece panel 42between the rim 30 b and contact point 24 of the roller 12 and againstspacer 37 d. This force profile is such that bending or flexure of thearticle 16 is reduced as it rides over the surface 13 of the roller 12.While the embodiment of FIG. 6 depicts mailpiece 64 oriented such thatpanel 42 rides against the surface 13 of the roller 12, mailpiece 64would be similarly suitably adapted to be oriented such that panel 44rides against the surface 13 of the roller 12. In this case, the beltpressure 28 would result in the article 16 and mailpiece 64 being tiltedsuch that article 16 is pushed against a portion of the mailpiece panel44 between the rim 30 b and contact point 24 of the roller 12 andagainst spacer 37 c. The resulting force profile would be such thatbending or flexure of the article 16 is reduced as the mailpiece 64 istransported across the surface 13 of the roller 12.

Spacers 37 c,d and article 16 are located in the mailpiece 64 such thatthe spacers 37 c,d are disposed between the article 16 and roller 12.Spacers 37 c,d may be rigid and non-compressible, such that nodeformation occurs under the influence of the belt pressure 28.Alternatively, the spacers 37 c,d may be substantially rigid, such thatnegligible deformation occurs under the influence of the belt pressure28 and thickness, t₃, is substantially maintained. In an alternativeembodiment, if the spacers 37 c,d are non-rigid, their thickness ischosen to compensate for any deformation that occurs under the influenceof the belt pressure 28 such that the compressed thickness, t₃, issufficient to mitigate the flexing. Any cushioning effect provided bythe spacers 37 c,d is incidental to the mitigation of the flexing of thearticle 16.

With reference to FIGS. 7-12, in which like reference numerals refer tolike features in FIGS. 4-6, various exemplary embodiments of mailpiecesin accordance with the principles of the invention are shown.

With reference to FIGS. 7, 7A, and 8 in which like reference numeralsrefer to like features in FIGS. 1-6 and in accordance with analternative embodiment of the invention, a mailpiece 23 a includesspacers 60 a-c arranged in a configuration similar to spacers 38 a,b, 40a,b (FIG. 4). Spacers 60 a,b each comprise a respective elongated member61 a,b secured by securing members 63 a,b, respectively, with the innersurface of panel 42 of mailpiece 23 a. Spacers 60 c,d each comprise arespective elongated member 61 c,d secured by securing members 63 c,d,respectively, with the inner surface of panel 44 of mailpiece 23 a.Elongated members 63 a-d may have a length substantially equal to thelength, L, of the mailpiece 23 a, and may extend between the lateraledges 50, 52, although the invention is not so limited. Securing members63 a-d may each include adhesive portions at least in the areas thatcontact the inner surface of the respective one of the panels 42, 44.Alternatively, other suitable bonding methods or components such as, forexample, thermal-bonding components or mechanical stitching, may besubstituted instead of securing members 63 a-d for securing theelongated members 61 a-d with the inner surface of the respective panels42, 44.

When belt pressure 28 (FIG. 4) is applied, the behavior of mailpiece 23a and article 16 is similar to that described in the embodiment of FIG.4, which shows the general principles for the behavior of mailpieceswith this type of spacer configuration. A person having ordinary skillin the art will appreciate that elongated members 61 a-d and securingmembers 63 a-d may have any other length relative to the length, L, ofmailpiece 23 a, or may alternatively have different lengths with respectto each other. In an alternative embodiment, the invention contemplatesthat mailpiece 23 a may include only spacers 60 a, 60 d (or 60 b, 60 c)arranged in compliance with the arrangement of spacers 37 a,b (FIGS.5A,B). In another alternative embodiment, the invention contemplatesthat mailpiece 23 a may include only spacers 60 a,c (or 60 b,d) arrangedin compliance with the arrangement of spacers 37 c,d (FIG. 6).

Mailpiece 23 a may further include a flap 56 integrally formed withpanel 42 along a fold line 47 and adjoining an opening 43 into the spacebetween panels 42, 44. The flap 56 has an adhesive region 58 suitable toadhere flap 56 to the outer surface of panel 44 or, alternatively, anyother non-adhesive coupling components suitable to couple the twoinvolved surfaces. A person having ordinary skill in the art willappreciate that the flap 56 may be characterized by a different shape,size, material, and/or relative location on mailpiece 23 a.Alternatively, the flap 56 may be omitted from the construction ofmailpiece 23 a.

With reference to FIG. 9 in which like reference numerals refer to likefeatures in FIGS. 1-8 and in accordance with an alternative embodimentof the invention, a mailpiece 23 b has spacers 68 (of which only aportion of one spacer 68 is shown for illustrative purposes) consistingof elongated adhesive beads bonded, adhered, or otherwise coupled to theinner surface of, for example, panel 42. The spacers 68 may made of anyother material suitable to be coupled to the inner surfaces of thepanels 42, 44, such as hot melt adhesives, cohesives, caulkingmaterials, and the like. Spacers 68 may have a length substantiallyequal to the length, L, of mailpiece 23 b and substantially extendingbetween lateral edges 50, 52. Alternatively, spacers 68 may be of anyrelative length and location with respect to the mailpiece 23 b and haveany non-tubular geometry or even an irregular cross-section effective tomitigate the flexing of the article 16.

In one embodiment, the spacers 68 may be arranged on panels 42, 44 ofmailpiece 23 b in compliance with the arrangement of spacers 38 a,b, 40a,b (FIG. 4) or spacers 60 a,b, 60 c,d (FIG. 8). In an alternativeembodiment, the invention contemplates that spacers 68 may be arrangedon panels 42, 44 of mailpiece 23 b in compliance with the arrangement ofspacers 37 a,b (FIGS. 5A,B). In another alternative embodiment, theinvention contemplates that the spacers 68 may be arranged on panels 42,44 of mailpiece 23 b in compliance with the arrangement of spacers 37c,d (FIG. 6).

With reference to FIG. 10 in which like reference numerals refer to likefeatures in FIGS. 1-9 and in accordance with an alternative embodimentof the invention, a mailpiece 23 c includes a plurality of spacers 70(only a portion of one row of spacers 70 is shown for illustrativepurposes), each of a length substantially smaller than the length, L,(FIG. 7) of mailpiece 23 c, positioned in series (e.g., a row) such thattheir cumulative end-to-end length may substantially extend betweenlateral edges 50, 52 (FIGS. 7, 10). Spacer 70 comprises a staple-likestructure made of deformable metal, plastic, or any other suitablematerial, having a general U-shape and including a main portion 70 a andtwo opposed leg members 70 b extending from the ends of main portion 70a. Each of the spacers 70 is adapted to deform between an open positionand a closed position coupled with a respective one of the panels 42,44. Spacer 70 engages the inner surface of, for example, panel 42 in thedirection shown by arrows 71, such that the leg members 70 b fold behindthe opposite, outer surface of each panel, as depicted by spacer 70′.While this embodiment describes serially positioned spacers 70 extendingsubstantially along the entire length, L, of mailpiece 23 c, persons ofordinary skill in the art will appreciate that spacers 70 may be of anyrelative length and location with respect to the mailpiece 23 c and haveany cross-sectional shape effective to mitigate the flexing of thearticle 16.

In one embodiment, the spacers 70 of mailpiece 23 c may be arranged onpanels 42, 44 of mailpiece 23 c in compliance with the arrangement ofspacers 38 a,b, 40 a,b (FIG. 4) or spacers 60 a,b, 60 c,d (FIG. 8). Inan alternative embodiment, the invention contemplates that spacers 70may be arranged on panels 42, 44 of mailpiece 23 c in compliance withthe arrangement of spacers 37 a,b (FIGS. 5A,B). In another alternativeembodiment, the invention contemplates that spacers 70 may be arrangedon panels 42, 44 of mailpiece 23 c in compliance with the arrangement ofspacers 37 c,d (FIG. 6).

With reference to FIG. 11 in which like reference numerals refer to likefeatures in FIGS. 1-10 and in accordance with an alternative embodimentof the invention, a mailpiece 23 d includes spacers 72 (only a portionof one spacer 72 is shown for illustrative purposes) of a lengthsubstantially equal to the length, L, (FIG. 7) of mailpiece 23 d, andsubstantially extending between lateral edges 50, 52 (FIGS. 7, 11).Spacer 72 comprises a Z-folded section 73 of, for example, panel 42 thatlocally increases the relative thickness of panel 42. A securing member74 may be applied over the Z-folded section 73 to secure the fold inplace and prevent unfolding. Securing member 74, having a lengthsubstantially equal to that of the Z-folded section 73, may haveadhesive portions (not shown) or other suitable coupling components suchas, for example, mechanical, thermal or chemical components to secure itagainst the inner surface of each panel. Alternatively, Z-foldedsections 73 may include adhesive portions allowing it to retain thefold(s) in place without the need for securing members 74.

In one embodiment, the spacers 72 may be arranged on panels 42, 44 ofmailpiece 23 d in compliance with the arrangement of spacers 38 a,b, 40a,b (FIG. 4) or spacers 60 a,b, 60 c,d (FIG. 8). In an alternativeembodiment, the invention contemplates that spacers 72 may arranged onpanels 42, 44 of mailpiece 23 d to comply with the arrangement ofspacers 37 a,b (FIGS. 5A,B). In another alternative embodiment, theinvention contemplates that spacers 72 may be arranged on panels 42, 44of mailpiece 23 d in compliance with the arrangement of spacers 37 c,d(FIG. 6).

While the embodiment of FIG. 11 depicts and describes Z-folded sections73 and securing members 74 of respective lengths substantially equal tolength, L, of mailpiece 23 d, persons of ordinary skill in the art willappreciate that the folded sections may adopt a different non-Z-shapefolded configuration effective to mitigate the flexing of the article16. Likewise, Z-folded sections 73 and securing members 74 may have anyother length relative to the length, L, of mailpiece 23 d, or mayalternatively have different lengths with respect to each othereffective to mitigate the flexing of the article 16.

With reference to FIG. 12 in which like reference numerals refer to likefeatures in FIGS. 1-11 and in accordance with an alternative embodimentof the invention, a mailpiece 23 e includes spacers 76 (only one spacer76 is shown for illustrative purposes) of a length substantially equalto the length, L, (FIG. 7) of mailpiece 23 e, and substantiallyextending between lateral edges 50, 52 (FIGS. 7, 12). Spacer 76 may, forexample, comprise a stack of laminated flat members 78, 78′, 78″ coupledto the inner surface of, for example, panel 42. The flat members 78,78′, 78″ increases the local relative thickness of panel 42 in thatparticular section, thereby creating an effective spacer 76 on panel 42.Flat members 78, 78′, 78″ may be made of the same or differentsubstrates, have equal or unequal respective lengths, and have adhesiveportions (not shown) or other suitable coupling components such as, forexample, mechanical, thermal or chemical components to permit couplingwith adjacent flat rectangular members or the inner surface of a panel.Flat rectangular members 78, 78′, 78″ may be, for example, made of thesame substrate, have equal lengths and each have adhesive portions onone the respective sides.

While the embodiment of FIG. 12 depicts and describes spacers 76comprising flat members 78, 78′, 78″, persons of ordinary skill in theart will appreciate that the flat members 78, 78′, 78″ may adopt adifferent shape than rectangular. Alternate shapes for the flat members78, 78′, 78″ may, for example, include square, round, oval, triangularor polygonal members in any number and of any suitable dimensions andthickness effective to mitigate the flexing of the article 16. Likewise,flat, members 78, 78′, 78″ may have any other length relative to thelength, L, of mailpiece 23 e effective to mitigate the flexing of thearticle 16.

In one embodiment, the spacers 76 may be arranged on panels 42, 44 ofmailpiece 23 e in compliance with the arrangement of spacers 38 a,b, 40a,b (FIG. 4) or spacers 60 a,b, 60 c,d (FIG. 8). In an alternativeembodiment, the invention contemplates that spacers 76 may arranged onpanels 42, 44 of mailpiece 23 e in compliance with the arrangement ofspacers 37 a,b (FIGS. 5A,B). In another alternative embodiment, theinvention contemplates that spacers 76 may be arranged on panels 42, 44of mailpiece 23 e in compliance with the arrangement of spacers 37 c,d(FIG. 6).

Embodiments of the invention contemplate that the spacers may be carriedon a separate sleeve that is inserted into the mailpiece, as opposed tospacers directly carried by the mailpiece. The spacers may also comprisean insert that is loosely placed inside a mailpiece. The inventioncontemplates that the sleeve or insert(s) may include any of the spacerstructures described above in connection with FIGS. 7-12 for mitigatingor reducing the stress applied to the article when the belt pressurecauses the mailpiece and the sleeve or insert to conform to the curvedshape of the crown of a crowned roller.

With reference to FIGS. 13A,B in which like reference numerals refer tolike features in FIG. 7 and in accordance with an alternative embodimentof the invention, a mailpiece 23 g, which is otherwise similar in mostrespects to mailpiece 23 a (FIG. 7), includes a sleeve 84 adapted tohold the frangible article 16. Sleeve 84 is configured with spacers inthe form of a series of semi-circular foldable flaps 94 a,b foldedagainst the respective back surfaces of each panel 85, 87 in respectivedirections indicated by arrows 95 a, 95 b. The flaps 94 a,b effectivelyincrease the local thickness of the sleeve 84.

Sleeve 84 may be a generally rectangular or square assembly formed oftwo opposed panels 85, 87, having top and bottom peripheral edges 90,92, and lateral or side edges 86, 88. Bottom edge 92 may be folded tocontact the outer side of panel 85, thereby enclosing the sleeve 84 andcontaining article 16. The folded section along bottom edge 92 may ormay not have adhesive, or other suitable coupling components, permittingcoupling with the outer side of panel 85. Alternatively, the foldedsection along the bottom edge 92 may be omitted.

The flaps 94 a,b originate from semi-circular apertures 93 a,b punchedthrough the constituent material of sleeve 84. The apertures 93 a,b areformed at selected locations on each of the panels 85, 87 so that theflaps 94 a,b comply with the arrangement of spacers 37 a,b (FIGS. 5A,B).Apertures 93 a,b and flaps 94 a,b may be generally aligned in adirection parallel to top and bottom edges 90, 92 of sleeve 84, suchthat a first set of flaps 94 a may be adapted to lie on panel 85 eitherabove or below the central axis 19 of article 16, while a second set offlaps 94 b may be adapted to lie on panel 87 on the opposite side (i.e.above or below) of central axis 19 of article 16. In the exemplaryembodiment of FIGS. 13A,B, the first set of flaps 94 a from apertures 93a on panel 85 lies below central axis 19 of article 16 and the secondset of flaps from apertures 93 b on panel 87 lies above central axis 19of article 16. Alternatively, the first set of flaps 94 b on panel 85may lie above central axis 19 of article 16 while the second set offlaps 94 a on panel 87 may lie below central axis 19 of article 16,which is in compliance with the arrangement of spacers 37 c,d (FIG. 6).

While sleeve 84 is depicted having two sets of flaps 94 a,b from threesemi-circular apertures 93 a,b, persons of ordinary skill in the artwill appreciate that sleeve 84 may alternatively, comprise any othernumber of flaps and apertures of any suitable shape (other thansemi-circular), such as square, rectangular, triangular, oval orpolygonal.

Article 16 may be placed within sleeve 84, which may in turn be insertedinto mailpiece 23 g in the direction indicated by arrow 98, therebydefining the configuration of the general embodiment depicted in FIGS.5A,B. Upon application of belt pressure 28, the mailpiece 23 g andarticle 16 behave similar to the behavior described with regard to theembodiment of FIGS. 5A,B. The sleeve 84 is located inside the mailpiece23 g, the flaps 94 a,b are located on the sleeve 84, and the article 16is located inside the sleeve 84 such that the flaps 94 a,b intervenebetween the article 16 and roller 12.

With reference to FIGS. 13C,D in which like reference numerals refer tolike features in FIGS. 13A, B and in accordance with an alternativeembodiment of the invention, a sleeve 100, which is otherwise similar tosleeve 84, includes spacers in the form of round members 102 coupledwith the apertures 93 c,d. The sleeve 100 replaces sleeve 84 (FIGS.13A,B) in mailpiece 23 g. The apertures 93 c,d and round members 102 arealigned in a direction generally parallel to top and bottom edges 90, 92of sleeve 100. Apertures 93 c are adapted to lie on panel 85 eitherabove or below the central axis 19 of article 16. Apertures 93 d areadapted to lie on panel 87 on the opposite side of central axis 19. Thefirst set of apertures 93 c round members 102 on panel 85 lies belowcentral axis 19 of article 16 and the second set of apertures 93 d andround members 102 on panel 87 lies above central axis 19 of article 16.Alternatively, the first set of apertures 93 c and round members 102 onpanel 85 may lie above central axis 19 of article 16 while the secondset of apertures 93 d on panel 87 and round members 102 may lie belowcentral axis 19 of article 16. While apertures 93 c,d are depictedhaving a generally square or rectangular shape, persons of ordinaryskill in the art will appreciate that apertures 93 a,b may have anysuitable shape so long as such shape includes at least one straightedge.

Round members 102 are folded and coupled about a straight edge of eachaperture 93 c,d such that, when folded against the respective backsurfaces of each panel 85, 87, they effectively increase the thicknessof the sleeve 100 in the portions including the round members 102,thereby defining spacers similar to spacers 37 a,b (FIGS. 5A,B). Roundmembers 102 may be made, for example, of paper, cardboard, plastic,rubber, or other materials of suitable thickness. Round members 102 maybe adhesively bonded with the surfaces of panels 85, 87 or may becoupled therewith in a different manner.

While sleeve 100 is depicted having two sets of apertures 93 a, personsof ordinary skill in the art will appreciate that sleeve 100 may,alternatively, comprise any other number of apertures of any suitableshape (other than square) such as rectangular, triangular, oval orpolygonal. Sleeve 100 is depicted having two rows of diametricallyopposed (with respect to central axis 19 of article 16) apertures 93 a,thus attaining the arrangement of spacers 37 a,b (FIGS. 5A,B). However,sleeve 100 may alternatively comprise two confronting sets of apertures93 a lying on the same side (i.e. above or below) of central axis 19,thereby attaining the arrangement of spacers 37 c,d (FIG. 6). Similarly,round members 102 may be replaced with members of any other shapesuitable to be coupled about an edge or portion of apertures 93 a, whichmay alternatively be a slit instead of an aperture.

Article 16 may be placed within sleeve 100, which may in turn beinserted into mailpiece 23 g (FIG. 13A). Upon application of beltpressure 28, the behavior of the mailpiece 23 g, sleeve 100, and article16 is similar to that described in the embodiment of FIGS. 5A,B. Thesleeve 100 is located inside the mailpiece 23 g, the round members 102and apertures 93 c,d are located on the sleeve 100, and the article 16is located inside the sleeve 100 such that the round members 102intervene between the article 16 and roller 12.

With reference to FIG. 14 in which like reference numerals refer to likefeatures in FIG. 13A and in accordance with an alternative embodiment ofthe invention, a generally rectangular sleeve 104, which is similar tosleeve 84 (FIGS. 13A,B) and sleeve 100 (FIGS. 13C,D), includes a seriesof spacers in the form of projections or disks 105 a,b are coupled torespective inner surfaces of the panels 85, 87 at selected locations soas to meet the spacer configuration of the general embodiment of FIGS.5A,B. The sleeve 104 is folded in the direction indicated by arrow 114to thereby enclose frangible article 16. The sleeve 104 may replacesleeve 84 (FIGS. 13A,B) in mailpiece 23 g (FIGS. 13A,B).

Disks 105 a,b may be aligned in a direction generally parallel to topand bottom edges 90, 92 of sleeve 104, such that a first set of disks105 a,b is coupled to panel 85 either above or below the central axis 19of article 16, while a second set of disks 105 a,b is coupled to panel87 on the opposite side of central axis 19. In the exemplary embodimentof FIG. 14, a first set of three disks 105 b on panel 85 lie belowcentral axis 19 of article 16 while a second set of three disks 105 a onpanel 87 lie above central axis 19 of article 16. Alternatively, thefirst set of disks 105 b on panel 85 may lie above central axis 19 whilethe second set of disks 105 a on panel 87 may lie below central axis 19.

Disks 105 a,b, which project from the plane of the corresponding panel85, 87, effectively increase the local thickness of the sleeve 100. As aresult, the disks 105 a,b thereby define spacers with an arrangementsimilar to spacers 37 a,b (FIGS. 5A,B). In an alternative embodiment,the disks 105 a,b and another pair of similar disks (not shown) may bearranged in compliance with the arrangement of spacers 38 a,b, 40 a,b(FIG. 4) or spacers 60 a,b, 60 c,d (FIG. 8). In another alternativeembodiment, the invention contemplates that disks 105 a,b may bearranged in compliance with the arrangement of spacers 37 c,d (FIG. 6).While sleeve 104 is depicted having two rows of circular disks 105 a,bof three, persons of ordinary skill in the art will appreciate thatsleeve 104 may alternatively comprise any other number of circular disks105 a,b of any suitable size and shape (circular or non-circular), suchas square, rectangular, triangular, oval or polygonal.

Disks 105 a,b may be made of any suitable material such as rubber,plastic, cardboard, paper, film or any other type of substrate and mayhave a thickness in accordance with the amount of bending to whicharticle 16 would otherwise be exposed. Disks 105 a,b may be constructedfrom a non-rigid material, such as a cellular foam, with a thicknesschosen to compensate for any deformation or compression that occursunder the influence of the belt pressure 28 (FIG. 2) such that thecompressed thickness is sufficient to mitigate the flexing of article16.

Disks 105 a,b may be adhesively bonded to the respective inner surfacesof panels 85, 87 of sleeve 104. Alternatively, other suitable couplingcomponents may be included to secure disks 105 a,b on the surface ofpanels 85, 87 or alternatively disks 105 a,b may be integrally formedwith panels 85, 87. Disks 105 a,b may alternatively comprise pocketsfilled with a fluid either injected into the panels 85, 87 or created bylayering or laminating multiple sheets to form panels 85, 87.

Article 16 may be placed within sleeve 104, which may in turn beinserted into mailpiece 23 g (FIGS. 13A,B), thereby defining theconfiguration of the general embodiment depicted in FIGS. 5A,B. Uponapplication of pressure against the belts 11 (FIGS. 5A,B), the behaviorof the mailpiece, sleeve 104 and article 16 is similar to that describedin the embodiment of FIGS. 5A,B, showing the general principles of thebehavior of mailpieces having spacers with this type of configuration.The sleeve 104 is located inside the mailpiece 23 g, the disks 105 a,bare located on the sleeve 104, and the article 16 is located inside thesleeve 104 such that the disks 105 a,b intervene between the article 16and roller 12.

With reference to FIG. 15 in which like reference numerals refer to likefeatures in FIG. 13A and in accordance with an alternative embodiment ofthe invention, mailpiece 23 g (FIG. 13A) may include a sleeve 108adapted to receive frangible article 16. The sleeve 108 replaces sleeve84 (FIGS. 13A,B) in mailpiece 23 g. Circular spacers 110 a,b may bedisposed at selected locations on panel 87 and circular spacers 112 a,bmay be disposed at selected locations on panel 85 so as to comply withthe configuration of the general embodiment of FIG. 4. A first pair ofdiametrically opposed circular spacers 110 a, b may lie on panel 87while a second pair of diametrically opposed circular members 112 a,bmay lie on panel 85. When sleeve 108 is formed by bringing panels 85, 87together in the direction indicated by arrow 114, a pair of facingcircular spacers 110 a, 112 a may lie on one side (i.e. above or below)of central axis 19 of article 16, while a second pair of facing circularspacers 110 b, 112 b may lie on the opposite side of central axis 19.Circular spacers 110 a,b, 112 a,b effectively increase the thickness ofthe sleeve 108 in the portions including the spacers 110 a,b, 112 a,b,thereby defining spacers similar to spacers 38 a,b, 40 a,b (FIG. 4) orspacers 60 a,b, 60 c,d (FIG. 8).

In an alternative embodiment, the invention contemplates that one of thespacers 110 a,b and one of the spacers 112 a,b may arranged to complywith the arrangement of spacers 37 a,b (FIGS. 5A,B). In anotheralternative embodiment, the invention contemplates that one pair of thespacers 110 a,b, 112 a,b may be omitted to provide an arrangement incompliance with the arrangement of spacers 37 c,d (FIG. 6). While sleeve108 is depicted having two pairs of circular spacers 110 a,b, 112 a,b,persons of ordinary skill in the art will appreciate that sleeve 108 mayalternatively comprise any other number of pairs of spacers of anysuitable size or shape (other than circular), such as square,rectangular, triangular, oval or polygonal.

Article 16 may be placed within sleeve 108, which may in turn beinserted into mailpiece 23 g (FIGS. 13A,B), thereby defining theconfiguration of the general embodiment depicted in FIG. 4. Uponapplication of pressure 28 against the belts 11 (FIG. 4), the behaviorof the mailpiece and article 16 is similar to that described in theembodiment of FIG. 4, showing the general principles of the behavior ofmailpieces having spacers with this type of configuration. The sleeve108 is located inside the mailpiece 23 g, the 1 10 a,b, 112 a arelocated on the sleeve 108, and the article 16 is located inside thesleeve 108 such that the 110 a,b, 112 a intervene between the article 16and roller 12.

The invention contemplates that the mailpiece itself, rather than asleeve inserted into a mailpiece, may include any of the spacerstructures described above in connection with FIGS. 14 and 15 formitigating or reducing the stress applied to the article when the beltpressure causes the mailpiece to conform to the curved shape of thecrown of a crowned roller.

With reference to FIG. 16 in which like reference numerals refer to likefeatures in FIG. 7 and in accordance with an alternative embodiment ofthe invention, a mailpiece 23 h similar in most respects to mailpiece 23a (FIG. 7), includes a pair of spacers in the form of rectangularinserts 118 a,b. Each of the inserts 118 a,b may be a generally flat,rectangular member defined by top and bottom edges 124, 126 and lateraledges 120, 122 and having a length substantially extending across theopening 43 of mailpiece 23 h. Inserts 118 a,b may be made of anysuitable material to provide the functionality of the spacers 37 c,d(FIG. 6), thereby limiting bending of article 16 when riding over thesurface 13 of a crown roller 12 (FIGS. 1-3). Since inserts 118 a,b maybe in direct contact with the article 16, the material and constructionof inserts 18 may also be suitable to contact the surfaces of frangiblearticle 16 without damaging such contacting surfaces.

Inserts 118 a,b are positioned such that they both lie generally facingeach other but respectively adjacent opposite sides 117, 119 of thearticle 16. Persons of ordinary skill in the art will appreciate thatinserts 118 a,b may have a different length and/or height, have a shapeother than rectangular, have different respective thicknesses, be madeof two different materials or both be placed at a different locationwith respect to central axis 19 of article 16. Inserts 118 a,b mayalternatively be coupled along their respective lateral edges 120, 122thereby defining a sleeve of suitable dimensions to retain of article16. Inserts 118 a,b may also be coupled along their respective lateraledges 120, 122 and bottom edges 126 so as to define a pocket into whicharticle 16 may be inserted prior to insertion of the article 16 anddefined pocket into the mailpiece 23 h.

Article 16 and inserts 118 a,b may be inserted into mailpiece 23 h inthe direction indicated by arrow 130, with a final resting position asindicated by the phantom-line rectangle 132, thereby defining theconfiguration of the general embodiment depicted in FIG. 6. While theembodiment of FIG. 16 is depicted having two individual inserts 118 a,bseparable from mailpiece 23 h, an alternative embodiment may include aninsert 118 a,b pre-attached to the inner surface of either panel 42, 44and a separable insert 118 a,b adapted to be inserted along with article16 such that both inserts 118 a,b lie adjacent opposed sides 117, 119 ofthe article 16 when article 16 is within mailpiece 23 h. Uponapplication of pressure 28 (FIG. 6) against the belts 11, the behaviorof mailpiece 23 h and article 16 is similar to that of spacers 37 c,d(FIG. 6), showing the general principles of the behavior of mailpieceshaving spacers with this type of configuration.

With reference to FIG. 17 in which like reference numerals refer to likefeatures of FIG. 16 and in accordance with an alternative embodiment ofthe invention, a mailpiece 23 i similar to mailpiece 23 h (FIG. 16)includes a Z-shape sleeve 134 that is assembled with the frangiblearticle 16. Sleeve 134 comprises a main panel 141 and two end panels140, 142 integrally formed with main panel 141. Sleeve 134 may be foldedalong fold lines 144, 146 in a Z-fold configuration, thereby definingthe end panels 140, 142 and main panel 141. The Z-fold of sleeve 134 issuch that end panels 140, 142 lie diametrically opposed and adjacent toopposed sides 117, 119 of article 16. For example, end panel 140 may bedisposed adjacent to side 117 of the article 16 while end panel 142 maybe disposed adjacent to side 119 of article 16. Alternatively, end panel140 may confront against side 119 while end panel 142 may confront side117 of the article 16.

Sleeve 134 may be made of any suitable material to provide thefunctionality of the pairs of spacers 37 a,b (FIGS. 5A,B), therebylimiting bending of article 16 or when riding over the surface 13 ofcrown rollers 12 (FIGS. 1-3). Because sleeve 134 may be in directcontact with article 16, the material and construction of sleeve 134 mayalso be suitable to contact the surfaces of article 16 without damagingsuch surfaces. While sleeve 134 is depicted in FIG. 17 as shown, personsof ordinary skill in the art will appreciate that, alternatively, sleeve134 may have end panels of unequal respective lengths and/or heights orjointly have respective lengths and/or heights other than those shown,have a shape other than rectangular, have different respectivethicknesses, be made of two different materials or both be placed atdifferent locations with respect to central axis 19 of article 16.

Article 16 and sleeve 134 may be inserted into mailpiece 23i in thedirection indicated by arrow 130, thereby defining the configuration ofthe general embodiment depicted in FIGS. 5A-5B. Upon application ofpressure 28 against the belts 11 (FIG. 4), the behavior of mailpiece 23i and article 16 is similar to that described in the embodiment of FIGS.5A-5B, showing the general principles of the behavior of mailpieceshaving spacers with this type of configuration.

With reference to FIG. 18 in which like reference numerals refer to likefeatures in FIG. 15 and in accordance with an alternative embodiment ofthe invention, sleeve 108 may be modified to omit spacers 110 a,b, 112a,b but, in their place, to include spacers 80 a,b of a lengthsubstantially equal to the length of sleeve 108, and substantiallyextending between lateral edges 86, 88. Spacer 80 a comprises a foldedsection along edge 92 of panel 87 so as to locally increase theeffective thickness of panel 87. Spacer 80 b comprises a folded sectionalong edge 79 of panel 85 so as to locally increase the effectivethickness of panel 85. The spacers 80 a,b may each comprise any type offold such as a bifold, trifold or z-fold, such as to create a suitableeffective local thickness increase. Spacers 80 a,b may comprise adhesivemembers (not shown) to facilitate retention of the fold along each ofthe top and bottom edges 79 a. Alternatively, securing members, such asadhesive tape, or coupling components, such as staples, may be appliedover the folded sections to secure the respective folds of spacers 80a,b. The spacers 80 a,b are arranged in compliance with the arrangementof spacers 37 c,d (FIG. 6). The spacers 80 a,b may extend alongsubstantially the entire length of sleeve 108 or may have unequallengths and/or respective lengths that are shorter than 108 effective tomitigate the flexing of the article 16.

With reference to FIGS. 19, 20, and 20A in which like reference numeralsrefer to like features in FIGS. 1-3 and in accordance with analternative embodiment of the invention, a generally square orrectangular mailpiece 150 includes opposed panels 151, 153 defining amailpiece opening 155. The mailpiece 150 has top and bottom edges 154,156 and lateral edges 152 a,b. Mailpiece 150 may further include a flap157, integrally formed with panel 153 along a fold line (not shown),having an adhesive portion 157 a suitable to adhere flap 157 to theouter surface of panel 151 or any other non-adhesive components suitableto couple the two surfaces involved. A person having ordinary skill inthe art will appreciate that the flap 157 of mailpiece 150 may have adifferent shape, size, material, or relative location or the flap 157may be omitted so long as the configuration or mailpiece 150 is suchthat it protects and generally encloses the contents therein.

Mailpiece 150 further includes a spacer 158 coupled to the inner surfaceof one of the panels 151, 153 or integrally formed therewith. Spacer 158is adapted to fit into the center opening 21 of the article 16 and isvertically positioned within mailpiece 150 such that the spacer 158 willtraverse a path above or below circumference 26 of roller 12 (FIG. 2).Spacer 158 has a thickness or axial dimension, A, that is larger thanthe thickness of the article 16.

As best shown in FIG. 20A, spacer 158 includes a hub portion 160 and aflange portion 162 coupled to one end of the hub portion 160. When thespacer 158 is inserted into center opening 21, the hub portion 160projects beyond the plane of one side 117 of the article 16 and theflange portion 162 projects beyond the plane of the opposed side 119.The flange portion 162 is disposed between side 119 of the article 16and panel 153. Hub portion 160 may be of any suitable shape to provide asurface area against which panel 151 may be abutted. Flange portion 162may be of any suitable shape to provide a surface area against whichpanel 153 may be abutted. Once article 16 is placed into mailpiece 150,the effective thickness of the mailpiece 150 local to the central axis19 of the article 16 is increased. The diameter of flange portion 162 isgreater than the diameter of the center opening 21 of article 16.Consequently, belt pressure 28 (FIG. 3) cannot displace the spacer 158relative to the center opening 21 and hub 19.

The hub region 160 of the spacer 158 is diametrically smaller than thecenter opening 158. As a result, the article 16 is free to move andfreely rotate relative to the hub region 160, as opposed to beinganchored in the mailpiece 150. The location of the spacer 158 inside themailpiece 150 is based on the position of the article 16 relative to thecircumference 26 and opposite rims 30 a,b of the roller 12 (FIG. 2) inorder to optimize the mitigation. The shape of hub portion 160 can becircular, oblong or oval, stared, square, etc.

With reference to FIG. 20B, a mailpiece 150 a with opposed panels 151,153 includes a spacer 158 a. Spacer 158 a is illustrated as having auniform diameter across its axial dimension, A, which is perpendicularto the radius. As a result, spacer 158 a differs from spacer 158 (FIGS.19, 20, 20A) in that the hub and flange portions 160, 162 have aconstant diameter. When spacer 158 a is positioned in the center opening21, spacer 158 a does not contact either side 117, 119 of the article16. Spacer 158 a has a smaller diameter than the diameter of the centeropening 21 of article 16. The length is greater than a thickness betweenthe sides 117, 119 of the article 16. The invention contemplates thatthe spacer 158 a may be tapered along its length so long as the maximumdiameter is less than the diameter of the center opening 21 of article16.

With reference to FIG. 20C, a mailpiece 150 b has opposed panels 151,153 and a radially compressible and resilient spacer 158 b. Spacer 158 bmay be manually pre-compressed by the user prior to engaging it intocenter opening 21 of the article 16. Alternatively, the article 16 maybe pushed onto spacer 158 b, which causes radial compression of spacer158 b to occur and thereby allows positioning of the spacer 158 b insidethe center opening 21. Once positioned in the center opening 21, spacer158 b may expand, thereby comprising a central hub portion 161 b andopposed cylindrical flange portions 160 b, 162 b. Flange portion 160 bcontacts side 117 and flange portion 162 b contacts side 119.Alternatively, spacer 158 b may be such that, once engaged into centeropening 21, spacer 158 b expands to thereby comprise a spacer having anon-cylindrical central portion and/or non-cylindrical flange portions.

With reference to FIGS. 21A,B in which like reference numerals refer tolike features in FIGS. 1-3 and FIGS. 19, 20, 20A and in accordance withan alternative embodiment of the invention, mailpiece 150, includingspacer 158 and holding article 16, is shown transported by belts 11 overthe crowned surface 13 of a roller 12 such as the roller in theembodiment of FIG. 4 and the description of which may be referred to foran understanding of the roller of FIGS. 21A,B as well. The article 16and spacer 158 are positioned inside the mailpiece 150 to optimize theeffectiveness of spacer 158 in view of all mailpiece design parameters.For example, a lifting mechanism, such as inserts or a pocket (notshown), may be used to position the article 16 inside the mailpiece 150to optimize the effectiveness of the spacer 150 by ensuring that thecenterline of spacer 158 (which coincides with axis 19) does notcoincide with the circumference 26 of roller 12.

With reference to FIG. 21A, mailpiece 150 is oriented such that panel153 sides the roller 12 while belt pressure is applied in a direction asindicated by arrows 28 a. Spacer 158 is vertically positioned inmailpiece 150 such that the spacer 158 will traverse a path abovecircumference 26 of roller 12. Alternatively and although not shown,spacer 158 may be vertically positioned in mailpiece 150 such that thespacer 158 will traverse a path below circumference 26 of roller 12.Pressure 28 a exerted by the belts 11 onto the mailpiece 150 and thearticle 16 will result in the mailpiece 150 contacting the roller at apoint proximate contact point 24 of roller 12 and the outer surface ofthe spacer 158 adjacent to panel 153 deforming to conform to the crownsurface of the roller 12. Spacer 158 will indirectly contact (throughpanel 153) the roller 12 in a region generally above circumference 26.The bending or flexing of article 16 is substantially limited due to theabutment of hub 18 of article 16 against the inner surface of flangeportion 160, which remains substantially flat and parallel to hub 18.The bending or flexing of article 16 is further limited due to thepressure of the belts 11 being exerted onto the spacer 158, and not ontothe article 16, causing the deformation and relative motion of spacer158 with respect to the center opening 21 of article 16.

With reference to FIG. 21B, mailpiece 150 is oriented such that panel151 sides the roller 12 while belt pressure is applied in a direction asindicated by arrows 28 b. Spacer 158 is vertically positioned inmailpiece 150 such that the spacer 158 will traverse a path abovecircumference 26 of roller 12. Alternatively, spacer 158 may bevertically positioned in mailpiece 150 such that the spacer 158 willtraverse a path below circumference 26 of roller 12. Pressure exerted bythe belts 11 onto the mailpiece 150 and the article 16 will result inthe mailpiece contacting the roller at a point proximate contact point24 and in the outer surface of the spacer 158 adjacent to panel 151being deformed to conform to the crown profile of the roller 12. Spacer158 will indirectly contact (through panel 151) the roller 12 in aregion generally above circumference 26. The bending or flexing ofarticle 16 is substantially limited due to the pressure of the belts 11being exerted onto the spacer 158, and not onto the article 16, causingthe deformation and relative motion of spacer 158 with respect to thecenter opening 21 of article 16.

With reference to FIGS. 22A,B and in accordance with an alternativeembodiment of the invention, the invention contemplates that one or morespacers may be placed directly on the frangible article, as opposed tocarried on an insert loosely positioned inside a mailpiece, directlycoupled with a mailpiece, or carried by a sleeve inserted into themailpiece. Specifically, a frangible article 16 a, which is constructedotherwise similarly to article 16, includes a front side 117 a, a backside 119 a, a hub 18 a, a center opening 21 a, and a central axis 19 a.Article 16 a further includes annular spacers 170 a,b that areconcentric with center opening 21 a and located on the hub 18 a on arespective one of opposed sides 117 a, 119 a. Annular spacers 170 a,bmay be constructed from a flexible material that permits deformationwhen pressure 28 a from conventional belts 11 (FIGS. 21A,B) actsthereupon or may be composed of a rigid material that does not deformunder the influence of pressure 28 a. Annular spacers 170 a,b have adiameter larger than the diameter of the center opening 21 a such thatthey do not interfere with the writing and reading of informationrespectively to and from a media region 20 a of article 16 a.

The annular spacers 170 a,b may be adhesively bonded to the sides 117 a,119 a of the hub 18 a. Alternatively, the annular spacers 170 a,b may beintegrally formed with the article 16 a during, for example, a moldingprocess.

Article 16 a may be placed in mailpiece 150 with the central axis 19 apositioned such that the spacer 170 a,b traverse a path above or belowcircumference 26 of roller 12 (FIGS. 21A,B). The mailpiece 150 may beconfigured with a pocket, interior sleeve or the like, to place thearticle 16 a in this location. Upon exertion of belt pressure 28 b(FIGS. 21A, B), the behavior of article 16 a and the mailpiece 150 willbe as described for the general embodiment of FIGS. 21A,B, which may bereferred to for an understanding of this exemplary embodiment as well.

While the present invention has been illustrated by a description ofvarious embodiments and while these embodiments have been described inconsiderable detail, it is not the intention of the inventor to restrictor in any way limit the scope of the appended claims to such detail.Additional advantages and modifications will readily appear to thoseskilled in the art. Thus, the invention in its broader aspects istherefore not limited to the specific details, representative apparatusand method, and illustrative example shown and described. Accordingly,departures may be made from such details without departing from thespirit or scope of the general inventive concept.

1. A mailpiece for mailing an article having a first side and a secondside opposite to the first side, the mailpiece comprising: a firstpanel; a second panel joined to said first panel to define a firstperipheral edge, a second peripheral edge, and side edges connectingsaid first and second peripheral edges, said first and second panelsdisposed on the respective opposite sides of the article, and thearticle being positioned between said first and second edges; a firstspacer carried by said first panel, said first spacer disposed betweenthe first side of the article and said first panel; and a second spacercarried by said second panel, said second spacer disposed between thesecond side of the article and said second panel.
 2. A mailpiece formailing an article having a first side and a second side opposite to thefirst side, the mailpiece comprising: a first panel; a second paneljoined to said first panel to define a first peripheral edge, a secondperipheral edge, and side edges separating said second peripheral edgefrom said first peripheral edge; and a sleeve carrying the article, saidsleeve disposed between said first and second panels, and said sleevepositioned between said first and second edges, said sleeve including afirst spacer disposed between the first side of the article and saidfirst panel, and a second spacer disposed between the second side of thearticle and said second panel.
 3. A mailpiece for mailing an articlehaving a first side and a second side opposite to the first side, themailpiece comprising: a first panel; a second panel joined to said firstpanel to define a first peripheral edge, a second peripheral edge, andside edges separating said second peripheral edge from said firstperipheral edge, said first and second panels disposed on the respectiveopposite sides of the article, and the article being positioned betweensaid first and second edges; and an insert between said first and secondpanels, said insert including a first spacer disposed between the firstside of the article and said first panel and a second spacer disposedbetween the second side of the article and said second panel.
 4. Amailpiece for use with an article having a first side, a second sideopposite to the first side, and a center opening extending between thefirst and second sides, the mailpiece comprising: a first panel; asecond panel joined to said first panel to define a first peripheraledge, a second peripheral edge, and side edges separating said secondperipheral edge from said first peripheral edge, said first and secondpanels disposed on the respective opposite sides of the article, and thearticle being positioned between said first and second edges; and aspacer adapted to be inserted into the center opening of the article,and the spacer at least partially disposed between the first side of thearticle and said first panel.
 5. An apparatus for use with a mailpiece,the apparatus comprising: a frangible article having a first side and asecond side opposite to the first side; and a first spacer projectingfrom said first side of said frangible article, said first spaceradapted to be disposed between said first side of said frangible articleand the mailpiece.